Plasma Cutter Having High Power Density

Abstract

Systems and methods are provided for a torch power system having a high power density. In one embodiment, a system is provided that includes a torch power unit having a compressor and power electronics that include one or more power converters, wherein the torch power unit has a power output density of at least 2 watts per cubic inch, 80 watts per pound, or a combination thereof. A power conversion assembly for a torch power unit is provided that includes a single circuit board, a torch power converter mounted on the single circuit board, and a non-torch power converter mounted on the single circuit board. An electrical torch system is also provided that includes a circuit board and a power converter coupled to the circuit board, wherein the power converter includes a planar transformer, a foil wound transformer, or a combination thereof.

Description

BACKGROUND

[0001] The invention relates generally to metal cutting and welding systems, and more particularly to portable power units for such systems.

[0002] Some torch systems, such as a plasma cutting system, use plasma (e.g., high temperature ionized gas) to cut metal or other electrically conductive material. In general, an electrical arc converts a gas (e.g., compressed air) into plasma, which is sufficiently hot to melt the work piece while the pressure of the gas blows away the molten metal. The power output and flow of the gas can affect the performance of the system.

[0003] Such plasma cutting systems may be portable and only require a power source for operation. As portable plasma cutting systems become smaller and less costly to manufacture, such plasma cutting systems may be targeted at the consumer market. However, such systems must provide a relativity high level of power output yet still maintain the portability necessary for the consumer market. Typically, the power conve...

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